Power tool
A power tool in accordance with the invention includes a housing having a handle connected to the housing in at least one position and extending about the rear of the housing with first and second end portions positioned at least in part off the sides of the housing such that the handle allows an operator a range of locations about the housing to facilitate an effective two-handed grip to maintain control over the power tool. The power tool may include an actuator, such as a switch, to regulate power supplied to the tool's motor, and may automatically shift to deactivate the power tool when an unintentional impact above a predetermined magnitude is received by the power tool. The power tool may also include a recess for maintaining an accessory tool and may be designed so that it is both statically and dynamically balanced in order to provide a balanced tool both at rest and during operation, and in order to reduce the amount of vibration experienced by an operator during use of the tool.
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This application is a continuation-in-part of application Ser. No. 29/158,303, filed Apr. 2, 2002, now U.S. Pat. No. D,474,087 which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTIONThis invention relates generally to a power tool and, more particularly, to an electrically-powered polisher capable of orbitally moving a pad to polish a workpiece.
The tool industry offers a variety of power tools for performing work on various types of workpieces. One common shortcoming, however, is that the power tools do not offer a variety of effective positions with which an operator may grasp the power tool. For example, many power tools have designated handles with which the operator is to grasp the power tool, (e.g., one forward handle and one rearward handle, two side handles, etc.). By limiting the operator in this way, the power tool may become less comfortable to work with and more difficult to use for extended periods of operation.
In addition, current power tool configurations may force the operator to hold and actuate the power tool in a specific manner or with a specific hand, rather than provide the operator with the freedom to hold and actuate the tool as desired. For example, as mentioned above, some power tools may require the operator to hold a forward handle with one hand and a rearward handle with another and require the operator to actuate the power tool from the rear handle alone. This configuration may force the operator to turn the power tool on and off using a hand he or she does not feel comfortable using, or may force the operator to hold the tool in an uncomfortable manner so that the operator can actuate the power tool with the hand that feels most comfortable.
Current power tool handles also do not account for the varying hand sizes between operators. For example, power tool handles do not provide a variety of handle sizes from which the operator may choose in order to suit his or her hand size. Thus, while a single sized handle may be perfect for some operators, it may be too large or too small for other operators. In addition, current handles do not provide a structure that effectively enables the operator to “feel” where his or her hands are on the handle. Thus, the operator is required to break his or her concentration or focus on the workpiece in order to assure that his or her hands are properly positioned on the power tool. This distraction can be unacceptable to the operator, particularly when trying to position the tool on a specific portion of the workpiece.
Power tool designs also could add additional safety considerations. For example, some tools allow the operator to lock the actuator in the “on” position so that the operator does not have to continually apply force to the actuator in order to operate the tool. This feature is well accepted by the users. However, additional features could be added to accommodate the rare instance where the tool may be dropped during operation.
Furthermore, the use of accessories in conjunction with the operation of the power tool may also be necessary. For example, power tools tend to leave residual particles from the workpiece or from substances used on the workpiece that could be picked up at the time of operation. It would be advantageous if the accessories were readily available or proximate to the power tool itself. This would promote maintaining a clean and obstacle free work environment.
Another shortcoming associated with conventional power tools is that many do not attempt to balance the power tool both at rest and during operation. For example, many power tools are designed so that they are statically balanced (i.e., balanced at rest) but are not dynamically balanced. (i.e., balanced while in operation). This poses particular problems when the work element is to be applied to the workpiece in a uniform and even manner. If the tool is unbalanced while in operation, it can be very difficult, if not impossible, to apply the work element to the workpiece in the desired uniform or even manner. For example, when a random orbital polisher is unbalanced, it can be difficult to uniformly apply wax to and remove wax from the workpiece, which may even result in damage to the workpiece due to an excessive concentration of work on one portion.
Another shortcoming associated with dynamically unbalanced tools is that the operator often experiences an undesirable vibration of the tool while in operation. This tends to make it difficult to apply the work element uniformly over the workpiece and to make it uncomfortable to operate the power tool for both short and extended periods of operation.
SUMMARY OF THE INVENTIONA power tool in accordance with the invention includes a housing having a handle connected to the housing in at least one position and extending about the rear of the housing with first and second end portions positioned at least in part off the sides of the housing such that the handle allows an operator a range of locations about the housing to facilitate an effective two-handed grip to maintain control over the power tool. The first and second end portions of the handle may be enlarged with respect to the remainder of the handle and may include an outer elastomer surface to facilitate enhanced gripping for control over the power tool. In a preferred embodiment the outer elastomer surface is an elastomer injected overmolding located on the upper surfaces of the first and second end portions of the handle, and the enhanced gripping surfaces facilitate enhanced coordination of a two-handed grip on the handle to maintain control over the tool.
The power tool further includes a motor located at least partially within the housing and has a work element connected to and driven by the motor for working on a workpiece. Preferably the power tool will include an actuator, such as a switch, to regulate the power to the motor, with the switch being movable between an active position to allow power to the motor and a de-active position to generally prohibit power to the motor; thus, transitioning the power tool between an active state for working on a workpiece and a de-active state, respectively. Preferably, the switch is positioned such that it may be operated while a two-handed grip is maintained on the handle of the power tool. For example, the switch may be located in a predetermined spaced relation to the handle so that the switch is operable from either side of the power tool while a two-handed grip is maintained on the handle thereof.
A lever is preferably connected to the switch and movable to operate the switch between the active and de-active positions. The lever may include an operator which extends from the housing near at least one of the first and second end portions of the handle such that the switch can be transitioned between the active and de-active states while a two-handed grip is maintained on the first and second ends of the power tool. Preferably two operator portions will be provided, with one operator portion connected to the lever and extending from the housing near the first gripping position on the handle, and the second operator portion connected to the lever and extending from the housing near a second gripping position on the handle. The lever or operator portion may be elongated to provide a range of locations along the switch and along the handle from which the switch can be operated while maintaining the two-handed grip.
The actuator may further be configured to automatically shift to deactivate the power tool when an unintentional impact above a predetermined magnitude is experienced by the power tool. For example, the switch may be configured to automatically shift to deactivate the power tool when an unintentional impact above a predetermined magnitude is applied to one or more of the tool's front, rear, top, bottom and side wall portions, as well as the handle. In a preferred embodiment, the deactivation mechanism includes a spring (or springs) which bias the lever portion of the switch in the de-active or “off” state. When the actuator is placed in the active state, the spring is compress and is maintained in the compressed state by the frictional forces preventing the switch from returning to the “off” state. The power tool is automatically deactivated when an unintentional impact is applied that is of a magnitude sufficient enough to overcome the frictional force of the switch. Thus, when such a impact is experienced, the spring expands, thereby forcing the actuator into the off position, deactivating the power tool.
The power tool may also be designed so that it is both statically and dynamically balanced in order to provide a balanced tool both at rest and during operation, and in order to reduce the amount of vibration experienced by an operator during use of the tool. Each component of the power tool has a calculable mass, density and center of gravity, and can be statically and dynamically balanced in a manner characterized by the following equations. For example, the tool may be statically balanced as characterized by the equations:
msystemrsystem=mCWrCW+mPHrPH+mPADrPAD+mBOrBO=0
or
msystemxsystem=mCWxCW+mPHxPH+mPADxPAD+mBOxBO=0
msystemysystem=mCWyCW+mPHyPH+mPADyPAD+mBOyBO=0
wherein m denotes mass, subscript items CW, PH, PAD and BO denote the counterweight, pad holder, pad, and pad assembly bolt, respectively, r denotes a distance between the subscript item's center of gravity to the z-axis (which is defined by the motor output shaft), and x and y denote a distance between the subscript items center of gravity coordinate in the x and y plane, respectively, to the z-axis.
The tool may be dynamically balanced by making the angular momentum of the system parallel to the axis of rotation. This may be achieved by setting the net inertia forces Iyz and Ixz equal to zero in order to have no net moment on the system. Thus, the tool may be dynamically balanced as characterized by the following equations:
(IxOzO)system=(IyOzO)system=0
IX
IY
wherein I denotes inertia and O is a moment center taken at a point of origin, and the dynamically balanced equation denotes that a net product of inertia of the pad assembly about point O, is equal to zero for dynamic balance.
If desired, these equations can be altered to take into account additional components of the power tool so that the tool may be more accurately modeled and balanced. For example, static balance may be characterized by the equations:
msystemrsystem=mCWrCW+mPHrPH+mPADrPAD+mBOrBO+mBErBE+mSPrSP+mADrAD=0
or
msystemxsystem=mCWxCW+mPHxPH+mPADxPAD+mBOxBO+mBExBE+mSPxSP+mADxAD=0
msystemysystem=mCWyCW+mPHyPH+mPADyPAD+mBOyBO+mBEyBE+mSPySP+mADyAD=0
and the dynamic balance may be characterized by the equations:
(IxOzO)system=(IyOzO)system=0
IX
IY
wherein subscript items BE, SP, and AD denote the pad assembly bearings, spacer and adhesive, respectively. The equations may also be modified to take into account accessories which are used with the tool such as bonnets. In alternate embodiments, however, the equations may be altered to take into account fewer components of the power tool. For example, a tool manufacturer such as a polisher manufacturer, may conclude that a desired or sufficient balance may be achieved by simply taking into account the counterweight, pad and pad holder. Thus, the above equations may be altered to eliminate reference to the bolt.
In a preferred embodiment, the counterweight of the tool is specifically designed to balance the tool both statically and dynamically. For example, the counterweight may be designed in a manner characterized by the following equations:
mCWrCW=−(mPHrPH+mPADrPAD+mBOrBO)
IX
IY
As mentioned above, the equations can be modified to more accurately model the tool if desired. For example, the pad assembly bearings, spacer and adhesive may be accounted for by rewriting the equations as follows:
mCWrCW=−(mPHrPH+mPADrPAD+mBOrBO+mBErBE+mSPrSP+mADrAD)
IX
In a preferred embodiment, a counterweight designed to statically and dynamically balance the counterweight includes a first horizontal portion having first and second ends, and defining a first opening through which the motor shaft is disposed and a second opening through which the pad assembly shaft or bolt is disposed. The first horizontal portion is generally rectangular in shape and cross section and may include a first sleeve extending upward from the upper side of the horizontal portion about the circumference of the first opening such that the first sleeve and first opening coaxially define a threaded bore into which the motor shaft may be threaded, and a second sleeve extending downward from the lower side of the horizontal portion about the circumference of the second opening such that the second sleeve and second opening coaxially define a threaded bore into which the pad assembly shaft or bolt may be threaded.
The counterweight includes a generally rectangular connecting portion having first and second ends wherein the connecting portion is connected to the second end of the first horizontal portion via the first end of the connecting portion, and a second horizontal portion having first and second ends wherein the first end of the second horizontal portion is connected to the second end of the connecting portion such that the second horizontal portion is positioned generally parallel to the first horizontal portion. Collectively, the connecting portion and the second horizontal portion define an opening which separates the connecting portion and second horizontal portion into two leg members and allows for a desired mass to be reached so that the counterweight may be dynamically balanced.
First and second end members are connected to opposite ends of the counterweight. The first end member is connected to the second end of the second horizontal portion and has a generally arcuate shape, wherein the second end of the second horizontal portion is connected to the inner surface of the first end member. The second end member is connected to the first end of the first horizontal portion so that the second end member is generally positioned on the opposite side of the counterweight as the first end member.
The power tool may also include a recess for maintaining an accessory tool that is movable between the recess and a position remote from the recess to be used in connection with the power tool. In a preferred form, the housing defines a slot into which a brush type accessory tool may be inserted and stored, or from which the tool may be removed and used in connection with the power tool. The slot may include a groove that allows an operator to more easily remove the accessory tool, and, together with the accessory tool include a releasable locking mechanism which allows the accessory tool to be moved between a locked location on the power tool and an unlocked position remote from the power tool so that the accessory may be used in conjunction therewith.
Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common, but well-understood elements that are useful or necessary in a commercially feasible embodiment, are typically not depicted in order to facilitate a less obstructed view of various embodiments.
In
The housing 12 includes an upper housing shell 20 and a lower housing shell 22 which, when connected to each other, interface along a parting line 24. The upper housing shell 20 and lower housing shell 22 can be made of any suitably lightweight material and are preferably molded plastic parts. The upper housing shell 20 and the lower housing shell 22 are secured together by a number of screws 23 recessed in the lower surface of the handle 14 (see
As illustrated in
As illustrated in
The top surface 20e of upper housing portion 20 is slightly arcuate in a convex manner and provides a raised wall portion 20f near the rear of the housing which defines a vent or passage to the cavity 26, such as the elongated slot opening 20g illustrated in
As illustrated in FIGS. 3 and 9–11, the lower housing shell 22 is generally bowl-shaped and has surfaces or wall members corresponding to those of the upper housing shell 20 discussed above. More particularly, the lower housing member 22 is generally arcuate in shape with tapered side walls 22a–b and arcuate rear and front walls 22c–d, respectively. In addition, the lower housing 22 includes a generally planar bottom wall 22e, which defines an opening 22f through which an upstanding circular wall of the mounting plate 30 extends.
The lower housing 22 further defines a socket 27 for receiving at least a portion of actuator 90. More specifically, as illustrated in
The switch 90a is actuated between active and de-active positions via a lever 90b. The lever 90b preferably is generally ring shaped with a pivot member such as bar 90c located on one side and a switch engaging surface 90d located on the side opposite bar 90c. The bar 90c rests in a support member, such as collar 90e (
The lever 90b also has operators, such as paddle-like extensions, 90g–h that generally extend out from opposing sides of the lever 90b and through passages 29 (see
The lower housing shell 22 includes pedestals 35a–b to support biasing members, such as springs 36. A third pedestal 35c is also included to support additional electronic circuitry or components, such as a rectifier 37. The preferred pedestals 35 are posts extending upward from the inner surface of bottom member 22e and are integral with the lower housing portion 22. The top portion of each pedestal 35a–b defines a recess for receiving a portion of the coil spring 36. The top surface of pedestal 35c defines a bore for receiving a screw 37a to secure the rectifier 37 thereto. The other end of springs 36 are connected to the lever 90b via spring securing mechanisms, such as bosses 90j. The preferred bosses 90j are rounded studs projecting downward from the lower surface of the lever 90b. The bosses 90j are disposed within the end of the coil springs 36. That is, the ends of each of the springs 36 form a sleeve that extends over at least a portion of the boss 90j. This allows the lever 90b to compress the springs 36 between the lower surface of lever 90b and the upper surface of pedestals 35a–b without shifting and other displacement of the spring 36s. The springs 36 bias the lever 90b away from the switch 90a but allow the lever 90b to be pressed into contact with the pushbutton 90a when desired by the operator. Thus, the operator may activate or deactivate the tool 10 by pressing downward on either (or both) of the paddle extensions 90g–h causing the lever 90b to pivot about bar 90c and compress the springs 36 so that the switch engaging surface 90d engages the pushbutton switch 90a, thereby turning the tool on and off. Once released, the springs 36 return the lever 90b to its biased upper position away from engagement with the switch 90a.
As illustrated in
The mounting plate 30 is generally rectangular in shape and includes tabs 30a–b which extend outward and upward from opposing side portions of the plate 30. The tabs 30a–b define bores into which elongate screws 31 are thread in order to mount and secure the motor 28 to the mounting plate 30. The tabs 30a–b, like the ridge 74b in mounting plate 30, aid to align and secure the motor 28 and mounting plate 30 in position when the motor 38 is inserted into the openings 74c and 22f defined by the top portion 74a of the shield 74 and the lower wall 22a of the lower housing portion 22, respectively. For example, the tabs 30a–b must be inserted into correspondingly shaped grooves or notches 75 in the top 74a of shield 74 and in the bottom wall 22e of housing 12 in order for the motor 28 to be properly aligned in the cavity 26. The tabs 30a–b prevent the motor 28 from rotating once in position so that maximum torque may be supplied to the work element, such as pad 16.
As illustrated in
The handle 14 has a generally circular cross-section and is generally U-shaped about the housing 12 to provide the operator with a plurality of gripping locations to facilitate an effective two-handed grip to maintain control over the tool 10. More particularly, upper and lower handle portions 14a and 14b connect along the parting line 24 and are secured together by screws 23 or other fasteners which are inserted into recessed bores located in the lower portion 14b of the handle 14. The handle 14 is preferably parallel to the work element 16, as illustrated in
The enlarging of the handle ends 14c provides the operator with a multi-dimensional handle which offers greater control over the tool than conventional handle designs. For example, the enlarged ends 14c offer increased surface area on the handle thereby allowing the operator to use more of his or her hand to grip the tool and maintain a stronger grip. The enlarged ends 14c also allow the operator to maintain a forward grip on the end of the handle, which can assist the operator in drawing the tool 10 back towards the operator when working on a workpiece.
The enlarged ends 14c also allow the operator to “feel” the ends of the handle without the need to visually locate them. This allows the operator to focus more on the workpiece rather than requiring the operator to break visual contact with the workpiece to determine where the ends of the handle 14 are. For example, the enlarged ends 14c also provide the operator with a structural end stop for the handle. Furthermore, the enlarged ends 14c position the operators hands when grasped in locations which are generally centrally-balanced with respect to the tool 10 and generally balanced about the tools center of gravity. Another benefit associated with the enlarged ends 14c is that they provide the user with a variety of handle sizes to choose from so that different sized hands can be accommodated. The elastomer grip 88 is provided on the upper portion 14a of handle 14 to facilitate enhanced gripping control over the power tool 10. The elastomer grip is preferably added by way of an injection overmolding process. More particularly, the handle 14 is preferably formed by a plastic injection molding process, which is later followed by injection of a grip layer material to form grip 88. A preferred material for the elastomer grip is an elastomer/plastic blend, such as, for example, SANTOPRENE, which is a product of Advanced Elastomer Systems, L.P. of Akron, Ohio. The overmolded grip may be formed with a smooth outer surface or with a textured outer surface and provides a non-slip rubber (or rubber-like) gripping surface for the operator's hand to grasp. Preferably, the operator will grip the ends 14c of the handle 14 with his or her palm covering the grip 88 on the upper handle portion 14a and his or her fingers and thumb wrapping around the handle to grasp the lower handle portion 14b of the handle end 14c. Alternatively, however, the operator may grasp the handle along any of the plurality of locations about the U-shaped handle. Furthermore, additional portions of the handle 14 (or the entire handle) may be covered with an elastomer overmolding. For example, an overmolded grip portion may be included in the rear of the unit and/or on the lower handle portion 14a.
It should be understood that other materials may be used for the overmolding portions. For example, other thermal plastic elastomers or elastomer/plastic blends, such as rubber, nylon, butyl, EPDM, poly-trans-pentenarmer, natural rubber, butadiene rubber, SBR, ethylene-vinyl acetate rubber, acrylate rubber, chlorinated polyethylene, neoprene and nitrile rubber, may also be used for the overmolded grip 88. Another material which may be used for the overmolding is HERCUPRENE, which is manufactured by the J-Von company of Leominster, Mass.
It should also be understood that alternate embodiments of the apparatus may be provided with no elastomer overmolding whatsoever. For example, the tool 10 may be provided with a simple smooth plastic handle, or a textured plastic handle, created from a traditional plastic injection molding process. More particularly, the overmolding may be replaced with a textured surface, such as Rawal #MT-11605, a mold texturization process provided by Mold-Tech/Rawal of Carol Stream, Ill. Similarly, other mold texturization processes may be used to create a variety of textured surfaces.
As illustrated in
As illustrated in
The hollow design of the body 12, spokes 62a–b and handle 14 allow for a variety of alternate embodiments and wiring configurations to be made. For example, the actuator 90 may be located in either of the spokes 62a–b or in a portion of the handle 14. As another alternative, the power cord 94 may be directly connected to the housing 12 of the tool 10 rather than the handle 14.
Referring now to
As illustrated in
The generally frusto-conical portion 78f of pad support 78a has a hollow center region that houses bearings 40a–b and a spacer 98. The bolt 80 passes through the central openings in the bearings 40a–b and the spacer 98 and is threaded into the second bore 38b of the counterweight 38. The first pad 78b, the second pad 78c and the third pad 78d also have central openings or passageways through which the bolt 80 passes in order to be threaded into the counterweight 38. The end of bolt 80 includes an enlarged head to secure the pad assembly 78, including bearings 40a and 40b and spacer 98, to the tool 10. During operation, the pad 14 will be orbitally rotated about the z-axis of the tool (defined by output shaft 28a) when the motor 28 drives the shaft 28a and the counterweight 38.
For maintenance purposes, at least one small opening or notch 78h may be defined by the annular wall 78g of the pad support 78a so that a hand tool or other instrument can be inserted into the interior region between the pad support 78a and the skirt member 74 to prevent the counterweight 38 from rotating while the bolt 80 is being unscrewed and removed from the counterweight 38. This enables the pad assembly 78 to be removed from the tool 10 for access to the counterweight 38 and the screws and bolts connecting the skirt member 74 and other internal components (e.g., the motor 28, rectifier 37, etc.) in the housing 12. Such access may be required to repair or replace parts, including the pad assembly 78 or those parts internal to the housing 12, the spokes 62a–b and the handle 14.
As mentioned above, the tool 10 is preferably statically and dynamically balanced in order to provide a tool 10 that is balanced both at rest and in operation, and in order to reduce the vibration experienced when the counterweight 38 and pad assembly 78 are in motion. An illustration of the components and forces associated with the power tool 10 is illustrated in
msystemrsystem=mCWrCW+mPHrPH+mPADrPAD+mBOrBO=0
or
msystemxsystem=mCWxCW+mPHxPH+mPADxPAD+mBOxBO=0
msystemysystem=mCWyCW+mPHyPH+mPADyPAD+mBOyBO=0
wherein m denotes mass, subscript items CW, PH, PAD and BO denote the counterweight 38, pad holder 78a, pad 78b–d, and pad assembly bolt 80, respectively, r denotes a distance from the subscript item's center of gravity to the z-axis defined by motor output shaft 28a, and x and y denote a distance between the subscript items center of gravity coordinates from the z-axis. Thus, the counterweight 38 aids to offset the effects the pad assembly 78 and bolt 80 have on the output shaft 28a so that the tool 10 remains statically balanced.
The power tool 10 may also be dynamically balanced so that the angular momentum of the system is parallel to the axis of rotation (or z-axis). More particularly, the tool 10 may be dynamically balanced by determining the sum of moments about a point of origin, referred to hereinafter as point “O.” In a preferred embodiment, and as illustrated in
and the net inertia forces Iyz and Ixz are set equal to zero ((IxOzO)system=(IyOzO)system=0) in order to have no net moment on the system (i.e., dynamically balanced). Therefore, in a preferred embodiment, the tool 10 is dynamically balanced as characterized by the following equations:
(IxOzO)system=(IyOzO)system=0
IX
IY
wherein I denotes inertia and O is a moment center taken at a point of origin, and the dynamically balanced equation denotes that a net product of inertia of the pad assembly about point O, is equal to zero for being dynamically balanced. In the latter equation, IY
If desired, these equations can be altered to take into account more or less components of the power tool so that the tool may be modeled, analyzed and further balanced as desired. For example, the equations may be altered to take into account the pad assembly bearings 40a–b, spacer 98 and adhesive 76 in order to more accurately model and further balance the tool 10. If this is undertaken, the static balance of the tool may be characterized by the equations:
msystemrsystem=mCWrCW+mPHrPH+mPADrPAD+mBOrBO+mBErBE+mSPrSP+mADrAD=0
or
msystemxsystem=mCWxCW+mPHxPH+mPADxPAD+mBOxBO+mBExBE+mSPxSP+mADxAD=0
msystemysystem=mCWyCW+mPHyPH+mPADyPAD+mBOyBO+mBEyBE+mSPySP+mADyAD=0
and the dynamic balance may be characterized by the equations:
(IxOzO)system=(IyOzO)system=0
IX
IY
wherein subscript items BE, SP, and AD denote the pad assembly bearings 40a–b, spacer 98, and adhesive 76, respectively. The equations may also be modified to take into account accessories which are used with the tool such as bonnets. In alternate embodiments, however, the equations may be altered to take into account fewer components of the power tool. For example, it may be determined that certain portions of the tool have a minimal impact on the balance of the tool for a particular application and, thus, need not be taken into consideration due to their nominal affect. By way of example, a polisher designer may conclude that a desired or sufficient balance may be achieved by simply taking into account the counterweight 38, pad 16 and pad holder 78a. Thus, the above equations may be altered to eliminate reference to the bolt 80. The more items or components of the tool that are considered and taken into account, the more accurate the modeling of the tool will be; however, if certain items have a minimal impact or affect on the modeling of the tool, than they may be considered negligible and unnecessary to factor into the analysis.
In a preferred embodiment, the counterweight of the tool is specifically designed to balance the tool 10 both statically and dynamically. For example, the counterweight may be designed in a manner characterized by the following equations:
mCWxCW=−(mPHxPH+mPADxPAD+mBOxBO)
IX
IY
Assuming the y-axis is oriented such that msystemysystem=0 is satisfied, the last equation is approximately equal to zero.
If a more accurate model or balancing of the tool 10 is desired, the equations may be modified as follows:
mCWxCW=−(mPHxPH+mPADxPAD+mBOxBO+mBExBE+mSPxSP+mADxAD)
IX
where subscript items BE, SP and AD denote the pad assembly bearings 40a–b, spacer 98, and adhesive 76, respectively. In yet other embodiments, the equation may be amended to include accessories used with the tool 10, such as a bonnet (not shown). As mentioned above, the accuracy of the equation in modeling the tool 10 improves as more components of the tool 10 are accounted for. Thus, the latter equation will provide a more accurate model for the purposes of statically balancing the tool 10; however, the difference between the products of each equation may be so nominal that the former equation is sufficient to reach the desired balance.
In a preferred embodiment, the mass and distance associated with bolt 80 are approximately 3.2687×10−2 lbm and −0.33755 in, respectively. The mass and distance associated with the pads 78b–d are approximately 2.1164×10−1 lbm and −0.33755 in, respectively. The mass and distance associated with the pad holder 78a are approximately 3.64386×10−1 lbm and −0.33755 in, respectively. Using the above equation, this produces a counterweight with the properties mCWxCW=0.20547 lbm·in. and zCW=0.65 in. The masses and inertia values calculate out to:
IX
or
IX
Therefore, in this embodiment, the properties of the counterweight must satisfy mCWxCW=0.20547 lbm·in and IX
In a preferred embodiment, a counterweight designed to statically and dynamically balance the tool 10, as illustrated in FIGS. 15 and 16A–B, includes a first horizontal portion 38c, which defines bores 38a–b of the counterweight 38. More particularly, the first horizontal portion 38c is generally rectangular in shape and cross-section and has bores 38a–b disposed therein between first and second ends of the structure. The first bore 38a is internally threaded for receiving the motor output shaft 28a and has a sleeve or collar extending upward from the top surface of the horizontal portion 38c in order to increase the length of the bore 38a. The second bore 38b is internally threaded for receiving the bolt 80 connecting the pad assembly 78 to the tool 10 and has a sleeve or collar extending downward from the bottom surface of the horizontal portion 38c in order to increase the length of the bore 38b. The lengthened bores 38a and 38b increase the amount of the shaft 28a and bolt 80 disposed therein, which subsequently strengthens the mechanical connection made between the counterweight 38 and shaft 28a and between counterweight 38 and bolt 80.
A second horizontal portion 38e is connected to the first horizontal portion 38c via a generally vertical interconnecting portion 38d. More particularly, the portion 38d interconnects the second horizontal portion 38e such that it is generally parallel to the first horizontal portion 38c. Collectively, the connecting portion 38d and second horizontal portion 38e form a generally L shaped structure having a central opening 38f that generally divides the connecting portion 38d and second horizontal portion 38e into two parallel legs which allows for a desired mass to be reached so that the counterweight 38 may statically and dynamically balance the tool, as will be discussed in further detail below.
A first end member 38g extends from the second horizontal portion 38e on the end opposite the interconnecting portion 38d. The first end member 38g is arcuately shaped about the end of the second horizontal portion 38e, with the end of the second horizontal portion 38e being connected to the inner curved surface of the end member 38g and the end member 38g having a generally rectangular cross section at any given point there along. The radius of curvature of the end portion 38g preferably corresponds to that of the annular wall 78g of pad support 78a so that the end member 38g can rotate within the annular wall 78g without interference by the wall 78g.
A second end member 38h is connected to the first horizontal portion 38c on the side opposite the interconnecting member 38d. Thus, the first and second end members 38g and 38h are located on opposite sides of the counterweight 38. The second end member 38h is generally rectangular in shape and is generally centered off of the end of the first horizontal portion 38c. This configuration allows the counterweight 38 to be made out of less material, but yet supply a sufficient amount of revolutions per minute (RPMs) to rotate the pad assembly 78 as desired.
It should be understood that the above equations (or variations thereof) may be used to design a variety of components in order to statically and dynamically balance the tool. For example, the equations (or variations thereof) may be used to determine a variety of masses and centers of gravity for each component of the tool 10 in order to statically and dynamically balance the tool 10. In addition, the layout and configuration of the components of tool 10 may also be altered or specifically selected in order to achieve dynamic balance. For example, the spiral configuration of the adhesive 76 illustrated in
It should also be understood that the more components and features of the tool that are taken into account, the more accurate the equation's modeling of the tool 10 will be. The more accurate the modeling (e.g., accounting for adhesive 76, bearings, accessories such as bonnets, etc.) the better balanced the tool 10 will become. For example, the tool 10 may also include a fan to cool the motor and tool components, such as the one shown in broken line in
msystemxsystem=mBOxBO+mCWxCW+mPADxPAD+mPHxPH+mfxf=0
msystemysystem=mBOyBO+mCWyCW+mPADyPAD+mPHyPH+mfyf=0
IX
IY
where subscript item f denotes the fan properties. As before, we assume there are no y-components of center of gravity for any component, therefore msystemysystem=0. In addition, since the x-z plane and y-z plane are planes of symmetry the products of inertia Ixz=Iyz=Ixy=0. Also, since the motor is rotationally balanced xm=ym=0. Furthermore, IX
Although specific equations have been provided, it should be understood that such equations are provide as a preferred method for characterizing the power tool and its components, and are not meant to be deemed the sole way in which the power tool 10 can be statically and dynamically balanced. Thus, it should be understood that such balance can be achieved by a variety of equations and methods which are intended to be covered by the scope of this application. Once statically and dynamically balanced, the tool 10 will feel more balanced at rest and in operation and will be less affected by the rotation of the counterweight 38, the pad assembly 78 and other associated components.
Turning now to
More specifically, the actuator 90 in
In a preferred embodiment, the distal end of the tab 100a passes through a slot-like portion 104b of the socket 104 so that the tab 100a may be fully placed into its “on” position. The switch 100 provides a sufficient amount of friction to maintain the springs 36′ in their compressed position so that the actuator 90 remains in its “on” state until the operator lifts one (or both) of the paddle portions 90g′ and 90h′ to return the lever 90b′ to its spring biased “off” state. With such a configuration, the actuator 100 and springs 36′ may also serve as an automatic shutoff or de-activation mechanism in that the springs 36′ will force the switch 100 into its “off” position (wherein the post 100a is shifted up into its “off” position) when an impact of a magnitude great enough to overcome the friction holding the switch 100 in its “on” position is experienced by the tool. For example, if the tool 10 is accidentally dropped, the tool 10 maybe configured to react to the unintentional impact by automatically switching the switch 100 into its “off” position, thereby ceasing operation of the tool 10. Preferably the tool 10 will be setup to switch “off” when an impact of a predetermined magnitude (e.g., a threshold magnitude) is applied to one or more of the front, rear, side portions, top, bottom and handle of the power tool 10.
By way of example and not limitation, the tool 10 may be configured so that a force ranging between 0.2 lb–3 lb and higher will cause the actuator 90 to turn off. In a preferred embodiment, a force of approximately 1 lb is required to return the actuator 90 to its “off” state, which is of a high enough threshold to prevent shutoff due to very minor impacts and of a low enough threshold to cause shutoff due to dropping of the tool 10, such as a drop of three feet or more. The force required to deactivate the tool can be adjusted by selecting switches with more or less frictional resistance, and/or by increasing or decreasing the strength of the springs 36′ used in the tool 10. For example, the switch 100 may be selected such that it only requires a force of approximately 0.25 lb to return tab 100a to its “off” state.
Turning now to
The brush 110 is preferably of a shape that corresponds to the slot 112 and includes a grippable feature such as ridge 110a along its upper portion to assist the operator in removing the brush 110 from slot 112. Extending out from the lower portion of the brush 110 are bristles 110b which may be used to sweep up or away residual particles of the workpiece or materials used on the workpiece, such as dry wax. The brush 110 may also be provided with a releasable locking mechanism, such as a detent or such as stud 110c, which may secure the brush 110 into slot 112 by mating with a stud receiving surface or groove located on an inner surface of the slot 112 (not shown). With such a configuration, the accessory may be moved between a locked location on the tool 10 and an unlocked position remote from the tool 10 so that the accessory may be used in conjunction therewith.
Turning now to
In addition to the alternate electrical connector, tool 10 in
The tool 10 illustrated in
In addition to the alternate features discussed above, the tool 10 of
Turning now to
The tool 10 of
As illustrated in
The tool 10 of
In addition to the alternate features discussed above, the tool 10 of
The handle ends 14c′ of
Thus, it is apparent that there has been provided, in accordance with the invention, a power tool having components and features that fully satisfy the objects, aims, and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and scope of the appended claims. Applicant also intends this application to cover all methods of manufacturing the apparatus disclosed herein, including, but not limited to, the methods for dynamically balancing a power tool.
Claims
1. A power tool for working on a workpiece comprising:
- a housing having generally a front, rear and a pair of opposing side portions and a top and bottom, the housing defining a generally slot shaped recess for receiving and maintaining a brush type accessory tool that can be used to assist the power tool in working on a workpiece, the brush type tool being movable between the recess and a position remote from the recess to be used to assist the power tool in working on the workpiece;
- a motor located in the housing;
- a work element to be driven by the motor adjacent to the bottom of the housing for working on a workpiece;
- a handle being connected to the housing in at least one position, the handle having first and second end portions spaced apart from the housing and extending about the rear portion of the housing so that the first end portion is positioned at least in part at one of the side portions and the second end portion is positioned at least in part at the other of the side portions; and
- wherein the handle allows an operator a range of locations about the housing to facilitate desired control over the power tool.
2. A power tool according to claim 1 wherein the first and second end portions of the handle are enlarged with respect to the remainder of the handle.
3. A power tool according to claim 2 wherein the first and second end portions include an enhanced surface over at least a portion thereof to facilitate enhanced gripping for control of the power tool.
4. A power tool according to claim 3 wherein the enhanced surface comprises an outer elastomer surface to facilitate enhanced gripping for control of the power tool.
5. A power tool according to claim 4 wherein the outer elastomer surface comprises an elastomer injected overmolding at the first and second end portions of the handle.
6. A power tool according to claim 1 further comprising a switch electrically connected to the motor to transition the power tool between an active state for working on a workpiece and a de-active state, the switch being operable while a two-handed grip is maintained on the handle of the power tool.
7. A power tool according to claim 6 wherein the switch includes a lever portion extending from the housing near at least one of the first and second end portions such that the switch can be operated through the lever portion while a two-handed grip is maintained on the handle of the power tool.
8. A power tool according to claim 7 wherein the lever portion is elongated to provide a range of locations along the handle from which the switch can be operated while a two-handed grip is maintained on the handle of the power tool.
9. A power tool according to claim 8 wherein the lever portion extends from the housing near both the first and second end portions such that the switch can be operated from either end portion while a two-handed grip is maintained on the handle of the power tool.
10. A power tool according to claim 9 wherein the lever portion includes a generally circular ring portion.
11. A power tool according to claim 6 wherein the switch is automatically shifted to deactivate the power tool when an unintentional impact above a predetermined magnitude is experienced by the power tool.
12. A power tool according to claim 11 wherein the switch is automatically shifted to deactivate the power tool when an unintentional impact above a predetermined magnitude is applied to one or more of the front, rear and side wall portions, the top and the handle of the power tool.
13. A power tool according to claim 12 further comprising a spring to automatically shift the switch to deactivate the power tool when an unintentional impact above a predetermined magnitude is applied to one or more of the front, rear and side portions, the top and bottom portions, and the handle of the power tool.
14. A power tool according to claim 13 wherein the spring biases the lever portion of the switch.
15. A power tool according to claim 14 wherein at least two springs bias the lever portion of the switch.
16. A power tool according to claim 15 wherein the springs are coil springs.
17. A power tool according to claim 1 further comprising a polisher pad operable by the motor for working on a workpiece and a counterweight intermediate the polisher pad and the motor to move the polisher pad in a generally orbital path, the counterweight being generally dynamically balanced to reduce vibrations generated by the power tool.
18. A power tool for working on a workpiece comprising:
- a housing defining a recess for receiving and maintaining a brush type accessory tool;
- a motor positioned in the housing;
- a work element to be driven by the motor below the housing;
- a handle being connected to the housing in at least one position, the handle having first and second ends with an elongated portion extending therebetween, the handle ends and elongated portion defining a length of the handle and the handle being generally uniformly spaced apart from the housing throughout at least a majority of the handle length; and
- a brush type accessory tool to be used to assist the power tool in performing work on a workpiece, the brush type accessory tool being movable between a first position where the accessory tool is stored in the housing recess and a second position remote from the power tool housing to perform work on the workpiece.
19. A power tool according to claim 18 wherein the housing has front and rear portions and the handle extends about the rear portion of the housing.
20. A power tool according to claim 18 wherein the handle extends in at least an one hundred eighty degree arc about the housing.
21. A power tool according to claim 18 wherein the first and second end portions include an enhanced surface over at least a portion thereof to facilitate enhanced gripping for control of the power tool.
22. A power tool according to claim 21 wherein the enhanced surface comprises an elastomer injected overmolding applied to the first and second ends of the handle.
23. A power tool according to claim 18 further comprising a switch electrically connected to the motor to transition the power tool between an activated state for working on a workpiece and a deactivated state, the switch being operable while a two-handed grip is maintained on the handle of the power tool.
24. A power tool according to claim 23 wherein the switch forms a circular ring shaped body defining an aperture through which at least a portion of the motor is disposed, the switch further including first and second operators extending from the body and through the housing with the first operator being located near the first end of the handle and the second operator being located near the second end of the handle so that the switch may be operated from either handle end.
25. A power tool according to claim 18 further comprising a switch electrically connected to the motor to transition the power tool between an activated state for working on a workpiece and a deactivated state, wherein the switch is automatically shifted to deactivate the power tool when an unintentional impact above a predetermined magnitude is applied to the power tool.
26. A power tool according to claim 25 wherein the power tool includes a biasing mechanism to automatically shift the switch to deactivate the power tool when the impact is applied to the power tool.
27. A polisher according to claim 18 further comprising a switch electrically connected to the motor to transition the polisher between an activated state for working on a workpiece and a deactivated state, wherein the switch is automatically shifted to deactivate the polisher when an unintentional impact above a predetermined magnitude is applied to the polisher.
28. A polisher according to claim 27 wherein the polisher includes a biasing mechanism to automatically shift the switch to deactivate the polisher when the impact is applied to the polisher.
29. A power polisher for polishing a workpiece comprising:
- a housing defining a recess for receiving and maintaining an accessory tool;
- a motor positioned in the housing;
- a pad driven by the motor below the housing;
- a handle being connected to the housing in at least one position, the handle having first and second free ends forming substantially large gripping portions for maintaining control of the polisher; and
- a brush type accessory tool to be used to assist the polisher in performing work on a workpiece, the brush type accessory tool being movable between a first position wherein the accessory tool is stored in the recess and a second position remote from the polisher housing to perform work on the workpiece.
30. A polisher according to claim 29 wherein the housing has front and rear portions and the handle extends about the rear portion of the housing.
31. A polisher according to claim 29 wherein the handle extends in at least an one hundred eighty degree arc about the housing.
32. A polisher according to claim 29 wherein the first and second end portions include an enhanced surface over at least a portion thereof to facilitate enhanced gripping for control of the polisher.
33. A polisher according to claim 32 wherein the enhanced surface comprises an elastomer injected overmolding applied to the first and second ends of the handle.
34. A polisher according to claim 29 further comprising a switch electrically connected to the motor to transition the polisher between an activated state for working on a workpiece and a deactivated state, the switch being operable while a two-handed grip is maintained on the handle of the polisher.
35. A polisher according to claim 34 wherein the switch forms a circular ring shaped body defining an aperture through which at least a portion of the motor is disposed, the switch further including first and second operators extending from the body and through the housing with the first operator being located near the first end of the handle and the second operator being located near the second end of the handle so that the switch may be operated from either handle end.
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Type: Grant
Filed: Jan 6, 2003
Date of Patent: May 23, 2006
Patent Publication Number: 20030182749
Assignee: WMH Tool Group, Inc. (Palatine, IL)
Inventors: Christopher T. Boyer (Oak Park, IL), John T. Gerritsen (Carpentersville, IL), Mark R. Lytell (Glendale Heights, IL), Joel G. Delman (Chicago, IL), Peter J. Kopec (Park Ridge, IL)
Primary Examiner: John Kim
Assistant Examiner: Shay L. Balsis
Attorney: Fitch, Even, Tabin & Flannery
Application Number: 10/337,514
International Classification: A47L 11/10 (20060101); B60S 3/06 (20060101);